Controlled damper with proportional valve and cross-flow bypass sleeve

Abstract

A damper assembly comprises a tube defining a fluid compartment; and a piston slidably disposed in the tube and dividing the fluid compartment into a rebound chamber and a compression chamber. The piston defines a cross-flow passage and includes: a first check valve configured to allow fluid flow from the compression chamber into the cross-flow passage while blocking fluid flow in an opposite direction, a second check valve configured to allow fluid flow from the rebound chamber into the cross-flow while blocking fluid flow in an opposite direction, and a proportional valve configured to regulate fluid flow between the cross-flow passage and an outlet passage based on an electrical control signal. Fluid flow is directed through the proportional valve in a same direction during each of a compression stroke and a rebound stroke.

What is claimed is: 
     
         1 . A damper assembly comprising:
 a tube defining a fluid compartment; and   a piston slidably disposed in the tube and dividing the fluid compartment into a rebound chamber and a compression chamber, the piston defines a cross-flow passage and includes:
 a first check valve configured to allow fluid flow from the compression chamber into the cross-flow passage while blocking fluid flow in an opposite direction, 
 a second check valve configured to allow fluid flow from the rebound chamber into the cross-flow passage while blocking fluid flow in an opposite direction, and 
 a proportional valve configured to regulate fluid flow between the cross-flow passage and an outlet passage based on an electrical control signal. 
   
     
     
         2 . The damper assembly of  claim 1 , wherein fluid flow is directed through the proportional valve in a same direction during each of a compression stroke and a rebound stroke. 
     
     
         3 . The damper assembly of  claim 1 , wherein the piston further includes:
 a third check valve configured to allow fluid flow from the outlet passage to the compression chamber while blocking fluid flow in an opposite direction, and   a fourth check valve configured to allow fluid flow from the outlet passage to the rebound chamber while blocking fluid flow in an opposite direction.   
     
     
         4 . The damper assembly of  claim 1 , wherein the piston further includes a rebound valve assembly configured to regulate fluid flow from the cross-flow passage into the compression chamber during a rebound stroke. 
     
     
         5 . The damper assembly of  claim 4 , wherein the rebound valve assembly includes a rebound valve member defining a rebound valve passage, and a rebound valve disc covering the rebound valve passage and configured to deflect away therefrom to restrict fluid flow therethrough. 
     
     
         6 . The damper assembly of  claim 5 , wherein the rebound valve assembly further comprises said first check valve including said rebound valve member defining a first one-way passage extending therethrough, and a first one-way disc covering the first one-way passage and configured to deflect away therefrom to allow fluid flow therethrough in one direction while blocking fluid flow in an opposite direction. 
     
     
         7 . The damper assembly of  claim 1 , wherein the piston further includes a compression valve assembly configured to regulate fluid flow from the cross-flow passage into the rebound chamber during a compression stroke. 
     
     
         8 . The damper assembly of  claim 7 , wherein the compression valve assembly includes a compression valve member defining a compression valve passage, and a compression valve disc covering the compression valve passage and configured to deflect away therefrom to restrict fluid flow therethrough. 
     
     
         9 . The damper assembly of  claim 8 , wherein the compression valve assembly further comprises said second check valve including said compression valve member defining a second one-way passage extending therethrough, and a second one-way disc covering the second one-way passage and configured to deflect away therefrom to allow fluid flow therethrough in one direction while blocking fluid flow in an opposite direction. 
     
     
         10 . The damper assembly of  claim 1 , wherein the piston further includes:
 a rebound valve assembly configured to regulate fluid flow from the cross-flow passage into the compression chamber during a rebound stroke;   compression valve assembly configured to regulate fluid flow from the cross-flow passage into the rebound chamber during a compression stroke; and   a housing having a tubular shape defining an interior space containing said rebound valve assembly, said compression valve assembly, and said proportional valve.   
     
     
         11 . The damper assembly of  claim 10 , wherein the piston further includes the cross-flow passage extending between said rebound valve assembly and said compression valve assembly. 
     
     
         12 . The damper assembly of  claim 10 , wherein the piston further includes a cross-flow ring having an annular shape disposed between the rebound valve assembly and the compression valve assembly and within an interior space of the housing coaxial with and spaced apart from an interior surface thereof, with the cross-flow passage extending annularly around the cross-flow ring. 
     
     
         13 . The damper assembly of  claim 10 , further comprising: a crossflow bypass member including a flange portion located within the interior space of the housing between the compression valve assembly and the proportional valve, and a tubular portion extending from the flange portion away from the proportional valve and through at least one of the rebound valve assembly and the compression valve assembly. 
     
     
         14 . The damper assembly of  claim 13 , wherein the crossflow bypass member defines a first crossflow bypass passage providing fluid communication between the cross-flow passage and the an inlet passage for supplying fluid from the cross-flow passage to the proportional valve. 
     
     
         15 . The damper assembly of  claim 13 , wherein the crossflow bypass member defines a second crossflow bypass passage providing fluid communication between an outlet passage and the compression chamber for transmitting fluid from the proportional valve to the compression chamber. 
     
     
         16 . The damper assembly of  claim 13 , wherein the flange portion of the crossflow bypass member defines a third one-way passage extending therethrough and providing fluid communication between an outlet passage and the rebound chamber for transmitting fluid from the proportional valve to the rebound chamber, and wherein the crossflow bypass member further includes a third one-way disc covering the third one-way passage and configured to deflect away therefrom to allow fluid flow therethrough in one direction while blocking fluid flow in an opposite direction. 
     
     
         17 . The damper assembly of  claim 13 , further comprising:
 an end cap having a ring shape configured to fit within the interior space of the housing adjacent to an end thereof in fluid communication with the compression chamber; and   a check valve body having a tubular shape extending through a central bore of the end cap and containing a check valve allowing fluid flow into the compression chamber while blocking fluid flow in an opposite direction; and   wherein the crossflow bypass member further includes a second tubular portion extending from the tubular portion further away from the proportional valve and into the check valve body.   
     
     
         18 . The damper assembly of  claim 1 , wherein the tube of the damper assembly further defines a gas compartment containing a gas, and
 wherein the damper assembly further includes a gas cup disposed in the tube in sealing engagement therewith and slidable along a center axis A thereof to divide the fluid compartment from the gas compartment.   
     
     
         19 . A damper assembly comprising:
 a tube defining a fluid compartment; and   a piston slidably disposed in the tube and dividing the fluid compartment into a rebound chamber and a compression chamber, the piston defines a cross-flow passage and includes a housing having a tubular shape containing a proportional valve configured to regulate fluid flow between the cross-flow passage and an outlet passage based on an electrical control signal, wherein fluid flow is directed through the proportional valve in a same direction during each of a compression stroke and a rebound stroke,   wherein the housing of the piston defines a rebound flow passage therethrough providing fluid communication between the rebound chamber an interior space of the housing to allow fluid flow therethrough during each of a compression stroke and a rebound stroke.   
     
     
         20 . The damper assembly of  claim 19 , wherein the piston further includes:
 a rebound valve assembly configured to regulate fluid flow from the cross-flow passage into the compression chamber during a rebound stroke; and   compression valve assembly configured to regulate fluid flow from the cross-flow passage into the rebound chamber during a compression stroke,   wherein the housing further contains said rebound valve assembly, and said compression valve assembly.